Sectional shipping container and internal pods therefor



Dec. 23, 1958 A. v. BROGREN SECTIONAL SHIPPING CONTAINER AND INTERNALPODS THEREFOR Filed Jan.

2 Sheets-Sheet 1 INVENTOR AXEL. V. BROGREN ATTORNEY Dec 23, 1958 A. v.BROGREN SECTIONAL SHIPPING CONTAINER AND INTERNAL PODS THEREFOR FiledJan.

2 Sheets-Sheet 2 INVENTOR. AXEL V. BROGREN ATTORNEY States SEC'HUNALSHIPPING CONTAINER AND INTERNAL PODS THEREFOR Axel V. lirogren, Detroit,Mich, assignor to Parsons Corporation, Detroit, Mich a corporation ofMichigan This invention relates to the protective packaging of objects,such as helicopter rotor blades, for handling, shipment and storage.

Since failure of helicopter rotor blades in flight is ordinarilycatastrophic, it is of extraordinary importance that helicopter rotorblades be protected during handling, shipment and storage from everytype of shock and unintended physical contact. Further, the need forreplacement rotor blades is often such that they must be deiivered underconditions of rough handling. The practice heretofore existing, allutilizing ordinary wood packing boxes, and supporting rotor bladestherein by localized clamp supports at several points along their span,has not given the rotor blades sufficient protection to assure theirsafe delivery.

The purposes of the present invention include the following:

To provide a rugged reusable standardized metal shipping containersuited for the protective shipment of rotor blades of various types,together with individual reusable blade enclosures fabricated to fit thespecific contours of each type of blade and to furnish distributedsupport for each blade within the shipping container.

To provide a sectional outer shipping container consisting of a bottomsection, a top section and any selected number of spacer sections,adapted to support a rotor blade or other elongated object at each jointof the sectional container.

To provide a sectional shipping container formed of sheet metal havingoutstanding flanges stabilized in simple fashion against deformation orwarping under contemplated applied loads, and having provision fornested stacking and lifting by forklift trucks.

To provide for such sectional container, blade support pods adapted tosupport the weight of the rotor blades in distributed fashion and tosupport the blades individually protected from contact with the walls ofthe shipping container and from each other. 4

To provide as a separate article of manufacture, reusable protectivepods for rotor blades and other elongated objects within which they maybe enclosed and protected during handling and storage and which affordcushion support during shipment.

To construct such protective pods in segments of a size readily formedand adapted for easy assembly, and to provide means for the readyalignment thereof and securement within a sectional shipping container.

Additional purposes and advantages of the present invention will beapparent from the description which fol lows.

In the accompanying drawings (2 sheets):

Figure 1 is a perspective view of a rotor blade shipping containerassembly embodying the present invention, broken away to show a rotorblade in the upper support pod thereof.

Figure 2 is an elevational view of the shipping con- :tainer shown inFigure 1.

2853,499 Patented Dec. 23, 1958 Figure 7 is a partial plan view of amodified pod construction.

Figure 8 is an enlarged root end elevation of the moditied form of podshown in Figure 7, the cavity therein being indicated in dashed lines.

Figure 9 is an enlarged fragmentary sectional view taken along line 9-9of Figure 7.

Figure 10 is a fragmentary section taken along line ill-ill of Figure 2.

Figure 11 is a fragmentary section taken along line 11-11 of Figure 4.

Figure 12 is an exploded perspective view of a quick fastener of thetype shown in both Figure 10 and Figure l1.

Referring now to the drawings by part numbers, I utilize a sectionalmetal shipping container generally designated 11, having a container topsection 12, a container bottom section 13 provided with a welded supportstructure 14, and one or more intermediate spacer sections 15, securedtogether by fasteners hereinafter described. The general organization ofthe sectional shipping container 11 is shown in perspective, elevationand section in Figures 1, 2 and 3, respectively.

The container top section 12 is formed of sheet metal to the shape of aninverted shallow trough, having a substantially flat top Wall 16, andhaving top section side walls 17 formed downwardly therefrom,terminating in an outstanding top section flange or rim 18 in the planeof its lower edge. It is preferably assembled by spot welding, usingfamiliar techniques and reinforcements such as the top section cornerreinforcements 19. The depth of the top section 12 is somewhat greaterthan half the maximum thickness of a rotor blade to be shipped in thecontainer, as is illustrated in Figure 3. Further reference will be madehereinafter to the clearance provided around the rotor blades.

The container bottom section 13 is formed to a size and in a mannersimilar to the container top section 12, and includes a substantiallyfiat bottom wall 20, from which the bottom section side walls 21 risesubstantially vertically to an outstanding bottom section flange or rim22 in the plane of its upper edge.

Arranged at intervals laterally across thebottom wall 29 and extendingslightly to both sides thereof are lateral support tubes 23, whoseoutstanding ends 24- rest upon a pair of longitudinal skid tubes 25 andare secured thereto by the welded support structure brackets 26. Thelongitudinal skid tubes 25 are spaced from each other a distanceslightly greater than the Width of the top section 12, exclusive of itsflanges, and the diameter of the skid tubes 25 is somewhat less than theheight of the top section side walls 17. This construction per mits thesecure stacking of one sectional container 11 upon another similarcontainer, the lateral support tubes 25 of the upper container restingon the substantially fiat top wall 16 of the container beneath it, andthe longitudinal skid tubes 25 of the upper container straddling the topsection side walls 17. The spaces between the lateral support tubes 23,the bottom wall 20, and the longitudinal skid tubes 25 permit access forlifting by fork lift trucks. Either a single shipping container or anested stack of containers can be readily lifted and transported.

The longitudinal skid tubes have upwardly swaged protruding ends 27 ofsuch length as to extend protectively beyondthe outstanding flanges 18and 22 of the top and bottom sections 12 and 13, respectively, as wellas of the spacer section or sections 15, hereinafter described.

Each spacer section 15 has an upper spacer flange 2S and a lower spacerflange 29 in the planes of the outer and lower margins, respectively, ofthe spacer section wall designated 30. This wall encloses a space ofsubstantially the same area as the area of the top section 12 or bottomsection 13 at their flanges 18. The spacer flanges 28, 29 and the topand bottom flanges 18, 22 are substantially co-extensive, as shown.

Referring to Figures 1 and 2, it is to be noted that the container topsection flange 18 and the container bottom section flange 22 areunsupported prior to the assembly of the shipping container 11. Incontrast, the upper and lower spacer section flanges 28, 29 have attheir corners the welded vertical corner brackets 31, and at intervalsalong the longer edges of the spacer section flanges 28,

29, these flanges are supported by a plurality of vertical anglebrackets 32 welded thereto. The purpose of the corner brackets 31 andangle brackets 32 is not to stabilize merely the flanges 28, 29 of thespacer section 15, but, by means of the flange fasteners hereinafterdescribed, to stabilize as well the top section flange 18 of the bottomsection flange 22. External forces which might cause flange deflectionor warping include forces arising from striking the container forciblyand buckling forces from the application of heavy loads to the containertop section 12. In case of application of any such external force, theintegration of the several outstanding flanges mto a structural unity,by use of suitable fasteners, will aid in avoiding buckling or warping.

Convenient means for effecting such structural integration, and at thesame time providing for the easy assembly and disassembly of thestructure, are shown in Figure 2. Mounted on the under sides of thebottom section flange 22, and. of the upper spacer flange 28 of eachspacer section 15, are a. plurality of quick fasteners 33 which mayconveniently be of the cam-lock type as shown in Figures 10 and 12, eachhaving a twist-locking pin 34 projecting vertically upward, from alevered cam portion. These quick fasteners 33 on the successive flangesare arranged in vertical alignment with each other.

The top section flange 18, and the lower spacer flange 29 I of eachspacer section 15, have elongated pin-accommodating apertures 35,likewise arranged in vertical alignment with each other and inregistration with the quick fasteners 33. The vertical twist-lockingpins 34 having cross-pins at their tops and the elongatedpin-accommodating apertures 35 fitted with spring receptacle plates 35,which accommodate such cross pins, make possible the quick assembly anddisassembly of the shipping container by vertical addition orsubtraction of the several container portions.

Reference will now be made to the manner of supporting objects such asrotor blades within the shipping container 11. Attention is directed tothe cut-away portion of Figure l and the sectional presentation ofFigure 3. From Figure 1 may be seen the manner of supporting a rotorblade, designated a, between the container top section 12 and the spacersection 15 therebeneath; this position corresponds with the upperposition shown in Figure 3, where the section is taken near the root endof blade a. Figure 3 also shows a section through approximately the tipend of a second rotor blade b mounted beneath the blade a. It is seenthat the blades are supported in separate blade pods, such as the poddesignated 36, shown in Figures 4, 5 and 6, and hereafter described.

Each blade pod 36 comprises an upper pod half 37 and a lower pod half38, each half formed of a moldable material such as resin-impregnatedlaminated fiber glass sheet or one of the family of post-formingplastics. Such materials are conveniently molded in a hot press. Theupper and lower pod halves 37, 38 are generally oblong in shape and haveplanar edges 39 which meet in a plane corresponding substantially to thechord plane of the rotor blade to be accommodated therein, or to themidplane of any other object to be shipped therein. intermediate theouter edges 39 of the upper pod half 37 is an upwardly-formed uppercavity half 40 whose shape is such as to accommodate and conform to thecontour of the rotor blade on one side of its chord plane. This uppercavity half 40 complements a lower cavity half 41, which is formeddownwardly in the lower pod half 38 to accommodate the contour of therotor blade on the other side of its chord plane. When the upper podhalf 37 and the lower pod half 38 are assembled in registration witheach other, the upper and lower cavity halves 40, 41 provide acontour-conforming sheath which supports the rotor blade evenly and withits weight distributed, protected against shock loads and chance contactas hereinafter more fully set forth.

On assembly of the upper and lower pod halves 37, 38, their planar outeredges 39 are presented in contact with each other. Likewise presented incontact are the cavity-bounding portions 42 which lie between the cavityhalves 40, 41 and the outer edges 39. Due to the twist of the blade (asshown by comparison of the tip end elevation, Figure 6 with the root endelevation, Figure 5) there is a warping of the blade chord plane, whichis particularly noticeable in the region of the blade tip. Thecavity-bounding portions 42 near the tip end are molded away from theplane of the outer edges 39, the mold line being designated 43 in Figure4.

Prior to assembly of the pod 36 with'the sectional shipping container11, the pod halves 37, 38 are preferably secured together by fastenersin the cavity-bounding portion 42, such as the pod mechanical fasteners44 shown adjacent the longer cavity margins 45 and illustrated inFigures 4, 5, 6 and 11. These fasteners 44 include a pin fastener ateach end, and serve to assemble the pod halves 37, 38 into an envelopein which a rotor blade may be protectively stored before and aftershipment. Another function of the pod fasteners 44 is to hold the cavityhalves 37, 38 in precise alignment, and to minimize their deflection.Like the quick fasteners 33 they may be of the commercially availabletype illustrated in Figure 12.

Where the molding of the cavity halves 37, 38 results in a fairly sharpbend, this bend adds additional rigidity. If the molding does notrequire a sharp angular bend, such additional rigidity may be obtainedby the use of strengthening beads, such as the trailing edge beads 46shown in Figure 6.

The outer edges 39 of the upper and lower pod halves 37, 38 have podedge apertures 47 corresponding in shape with and arranged inregistration with the elongated pinaccornmodating apertures 35. Thus arotor blade b may be secured by the pod quick fasteners 44 within a pod36; and the pod 36 then assembled over the container bottom section 13by lowering it vertically so that its edge apertures 47 are penetratedby the twist pins 34 of the fasteners 33 of the bottom section 13. Aspacer section 15 may be then assembled thereon and the quick fasteners33 tightly secured. Another rotor blade a may be similarly mounted in asecond pod 36 and secured in the same fashion above the upper spacerflange 28. If it is desired to ship rotor blades in groups of more thantwo (as for example, in sets of three or four) additional spacersections and pods may be added. The manner of securement of thecontainer top 12 is apparent.

The blade pods 36, when so mounted within the shipping container 11,serve as enveloping diaphragms. Not

only do they support the weight of the blades distributed over the lowersurface area, but theyresist shock loads in the manner of a diaphragmand maintain the blades separated and protected from chance contact withthe walls of the shipping container 11 and with each other. This isaccomplished with an economy of space. It is apparent that the verticalmovement of blades so supported will be slight, depending in part on thematerial characteristics of the sheet metal used to form the pods 36 andthe tolerance in the outer pod edge apertures 47.

One outstanding advantage of the present invention, however, is that thesectional shipping container 11 may be made to a standardized size largeenough to permit its use with a number of different rotor bladeconfigurations. Utilizing such a standardized shipping container, thepods 36 may be individually molded to the precise contour of each bladeconfiguration. With a standardized shipping container and a supply ofsuch pods molded for each specific blade configuration, the problem ofsupply of shipping containers is minimized and the advantage ofreusability is multiplied.

Many varied forms of pods and alterations in shipping containerstructure will occur to those familiar with the problems of shipment ofsuch articles. For example, provisions may be made for ventilation anddrainage, and for hermetic sealing.

The pods required for extremely long rotor blades may be difficult toform in halves. Accordingly, attention is directed to the alternate formof pod construction shown in Figures 7 and 8. Such alternate form of podis referred to as a segmental pod enclosure 48, and comprises aplurality of longitudinally-aligned upper pod segments 49, shown inFigure 7, and a plurality of corresponding lower pod segments 50. Thesemay be of any length convenient for forming and handling. Each of thepod segments has laterally opposite outer edge segment portions 51adapted to be assembled together to meet substantially in a plane, asshown in Figure 8. Intermediate the laterally-opposite edge portions 51are segmental cavity portions 52 which, on assembly as shown in Figure8, provide a single cavity conforming to the outer contour of the rotorblade to be accommodated therein.

Adjacent each lateral edge save the root and tip end edges, each segment49, 50 is provided with a lateral alignment bead 53 of such size as tonest with the corresponding alignment bead of the adjacent segment, asshown in Figures 7 and 9. The ends of the alignment beads 53 extendlaterally beyond the segmental cavity portions 52 into the pod segmentcavity-bounding portions 54, as shown in Figures 7 and 9. At theseportions the upper and lower pod segments 49, 59 are secured with thesuccessive longitudinal segments nesting overlappingly in alignment, andare held by simple fasteners such as bolted connections 55. Thesegmental pod enclosure is adapted for mounting within the shippingcontainer 11 by pod edge apertures 47' penetrating its outer edgesegment portions 51.

Either variant of pod structure, and other possible forms of pod, may becombined with the sectional shipping container 11 to compose aprotective assembly utilizable for a broad variety of products requiringprotection during shipment. The shipping assembly here disclosed hasbeen utilized with helicopter masts of generally circular section, andmay be readily adapted for a variety of other uses. Several objects maybe secured between the halves of a single pod, provided the pod issuitably molded. Thus, the slightly greater cost of a metal shippingcontainer over an ordinary wood shipping box is paid for many times overby reason of its reusability and its easy adaptation of the shipment ofarticles of varying configuration. Accordingly, the present inventionshould not be limited to the specific structures here illustrated, butshould be deemed as fully coextensive with the in- Yentive principlesdisclosed,

I claim: ,7

1. A segmental pod enclosure for a rotor blade, comprising a pluralityof longitudinally-aligned upper pod segments, each segment havinglaterally-opposite outer edge portions lying substantially in a planeand having a cavity portion therebetween formed upwardly, the adjacentsides of said upper segments being beaded and overlapping so that theircavity portions together define a cavity which substantially conforms tothe contour of a rotor blade, further comprising a plurality oflongitudinally-aligned lower pod segments, each segment havinglaterally-opposite outer edge portions lying substantially in a planeand having a cavity portion therebetween formed downwardly, the adjacentsides-of said lower segments being headed and overlapping so that theircavity portions together define a cavity which substantially conforms tothe contour of a rotor blade, and a plurality of mechanical fasteners inthe overlapping portions of said pod segments and positioned outwardlyadjacent the cavity portions and inward of the outer edge portions forsecuring the adjacent upper and lower pod segments together to form aprotective pod.

2. A sectional shipping assembly for protectively packaging a pluralityof airfoils arranged longitudinally with their chord planessubstantially horizontal at difierent levels, comprising an elongatedmetal shipping container having a container bottom section including abottom wall and said walls extending thereabove, the side walls havingan upper edge rim flange extending outwardly; skid means depending fromsaid bottom section arranged longitudinally parallel and spaced belowthe bottom wall; a container top section including a top wall and sidewalls extending downward therefrom and having an outwardly flanged loweredge rim; and an intermediate spacer section having an outwardly flangedupper edge rim and an outwardly flanged lower edge rim, coextensiverespectively with the lower edge rim of the container top section-andthe upper edge rim of the container bottom section; a first bladesupport diaphragm having a blade support cavity and diaphragm edgessubstantially coextensive with the upper edge rim of the spacer section,a second blade support diaphragm having a blade support cavity anddiaphragm edges substantially coextensive with the upper edge rim of thebottom section, and releasable securement means at said edges, wherebythe top section lower edge rim is secured to the edges of the firstdiaphragm and the spacer section upper edge and whereby the spacersection lower edge is secured to the edges of the second diaphragm andthe upper edge of the box bottom section.

3. Protective rotor blade shipment means comprising in combination anelongated sectional shipping container having a container bottomsection, a container top section and a frame-like spacer section, eachof said bottom, top and spacer sections having outstanding edges invertical registration with each other, and releasable mechanicalfastener means at said edges whereby said sections are releasablyassembled together vertically in registration; together with a firstprotective pod including a blade support diaphragm having a supportcavity and outer edges extending spacedly outward of said cavity betweenand substantially coextensive with the upper edges of the spacer sectionand a second protective pod having a support cavity and having outeredges between and substantially coextensive with the upper edges of thebottom section, each of said blade support diaphragms having ahorizontal planar portion intermediate its cavity and its outer edges,each pod further having an upper pod member including a contouredportion in registration with the cavity of the diaphragm of said pod anda horizontal planar portion thereabout, and fastener means securing theplanar portion of each upper pod member to the planar portion of itsblade diaphragm.

(References on following page) References Cited in the file of thispatent UNITED STATES PATENTS Leahy June 16, 1908 Flemming Jan. 17, 1911Caylor Aug. 3, 1926 Schweinkzin May 2, 1933 Kuepp'ers Oct. 27, 1942Larsen Mar. 21, 1950 8 Nicolle Dec. 11, 1951 Higbee Oct. 14, 1952Blackinton Apr. 6, 1954 Cohen June 15, 1954 Gould et a1 May 17, 1955FOREIGN PATENTS Great Britain May 22, 1919 France Apr. 4, 1951

